Structure-lining apparatus with adjustable width and tool for same

ABSTRACT

A structure-lining apparatus for lining one or more surfaces of a structure formed from curable material cast in a form. The apparatus comprises a plurality of panels. The panels are connected at their respective edges in an edge-to-edge connection to provide a structure-lining surface. A plurality of anchoring components project from the panels into the liquid material during fabrication of the structure. The anchoring components each comprise one or more anchoring features which are encased in the material as the material solidifies to thereby bond the anchoring components to the structure. The plurality of anchoring components comprises one or more connector-type anchoring components for connecting to corresponding connector-type anchoring components on adjacent edges of a corresponding edge-adjacent panel to connect the edge-adjacent panels in an edge-adjacent relationship. The apparatus comprises one or more breakaway components on at least one of the plurality of panels.

RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No.16/914,194 filed 26 Jun. 2020, which in turn is a continuation of U.S.application Ser. No. 16/012,743 filed 19 Jun. 2018 (now U.S. Pat. No.10/731,333), which in turn is a continuation of patent cooperationtreaty (PCT) international application No. PCT/CA2016/051548 which hasan international filing date of 29 Dec. 2016 and claims priority fromU.S. application No. 62/273,694 filed on 31 Dec. 2015. For the purposesof the United States, this application claims the benefit of 35 USC §199 in relation to U.S. application No. 62/273,694 filed on 31 Dec.2015. All of the applications referenced in this paragraph are herebyincorporated herein by reference.

TECHNICAL FIELD

The invention disclosed herein relates to fabricating structures fromconcrete and similar curable materials. Particular embodiments of theinvention provide methods and apparatus for providing linings on thesurfaces of concrete structures during fabrication thereof. Suchconcrete structures may include, without limitation, walls for buildingstructures or the like.

BACKGROUND

It is known to make a wide variety of structures from concrete. By wayof non-limiting example, such structures may include walls (e.g. forbuildings, tanks or other storage containers), structural components(e.g. supports for bridges, buildings or elevated transportationsystems), tunnels or the like.

In many applications, the concrete used to make such structures isunsuitable or undesirable as a surface of the structure or it isotherwise desired to line one or more surfaces of the structure withmaterial other than concrete.

By way of non-limiting example, consider the use of concrete to formtilt-up walls. Concrete tilt-up walls are typically formed in agenerally horizontal plane (e.g. on a horizontal table) and then tiltedto a generally vertical plane. A form is created on the table bysuitably fastening form-work members to the table such that theform-work members extend upwardly from the horizontal surface of thetable. Concrete is then poured into the form. The form-work members(including the horizontal surface of the table) retain the liquidconcrete in the desired shape. Concrete, prior to curing, or othercurable material, prior to curing, may be described herein as beingliquid, liquid concrete or liquid material for brevity. It will beappreciated by those skilled in the art that concrete, prior to curing,or other curable material, prior to curing, need not be a homogeneousliquid and may comprise solid particles within a mixture exhibitingliquid characteristics in contrast with cured concrete or curedmaterial, which is a solid. Some tables are configured to vibrate toassist with an even distribution of liquid concrete. When the concretesolidifies, the concrete structure is hoisted from the form and tiltedfrom the generally horizontal orientation of the table into a generallyvertical orientation by a crane, a suitably configured winchingapparatus or the like.

A drawback with prior art tilt-up walls is that all of the surfaces ofthe wall are bare concrete. Bare concrete surfaces have a number oflimitations. Bare concrete may be aesthetically unpleasing.Consequently, prior tilt-up walls may not be suitable for certainapplications where there is a desire to have an aesthetically pleasingfinished surface on the walls. In addition, bare concrete typically hasa somewhat porous or otherwise non-smooth surface which is difficult toclean and which provides spaces for dirt to accumulate and bacteria andother organisms to grow. Consequently, prior art tilt-up walls may notbe suitable for certain applications where there is a desire to providea sanitary environment. Bare concrete may be susceptible to degradationor damage from exposure to various chemicals or conditions, such as, byway of non-limiting example, salt, various acids, animal excrement andwhey. Consequently, prior art tilt-up walls may not be suitable forcertain applications where the wall might be exposed to such chemicals.

Various apparatus and methods for lining concrete structures/wallsexist. However, due to the widely varying shapes and sizes of concretestructures/walls, prior art concrete liners must be custom designed andfabricated for each application.

There is a general desire for efficient methods and apparatus for liningone or more surfaces of concrete structures with material other thanconcrete, without having to custom design and fabricate a lining foreach application.

SUMMARY

The following embodiments and aspects thereof are described andillustrated in conjunction with apparatus and methods which are meant tobe exemplary and illustrate, not limiting in scope. In variousembodiments, one or more of the above-described problems have beenreduced or eliminated, while other embodiments are directed to otherimprovements.

One aspect of the invention provides a structure-lining apparatus forlining one or more surfaces of a structure formed from curable materialcast in a form. The apparatus comprises a plurality of panels whichextend in substantially orthogonal transverse and longitudinaldirections and the panels are connectable at their respective transverseedges in an edge-to-edge connection to provide a structure-liningsurface. A first panel of the plurality of panels comprises a firstconnector component on a first transverse edge of the first panel, asecond connector component, complementary to the first connectorcomponent, on a second transverse edge of the first panel, a thirdconnector component, complementary to the first connector component,between the first and second transverse edges of the first panel, and afirst breakaway component between the second connector component and thethird connector component for shortening a transverse length of thefirst panel. A second panel of the plurality of panels is edge-adjacentto the first panel and is connectable in an edge-to-edge connection tothe first panel by a first complementary connector component that iscomplementary to the first connector component of the first panel or asecond complementary connector component that is complementary to thesecond and third connector components of the first panel.

Another aspect of the invention provides a method for lining one or moresurfaces of a structure formed from material that is cast as a liquidand subsequently solidifies. The method comprises providing a form inwhich to cast the material and providing a first and second panels whichextend in substantially orthogonal transverse and longitudinaldirections. A transverse dimension of the first panel is shortened bybreaking a first breakaway component of the first panel, whereinshortening a transverse dimension of the first panel comprises creatinga new transverse edge of the first panel. The first panel is connectedto the second panel in an edge-to-edge connection at the new transverseedge of the first panel and an edge-adjacent transverse edge of thesecond panel to provide a structure lining surface. The first and secondpanels are inserted into the form such that at least a portion of thestructure lining surface abuts against a corresponding portion of theform and liquid material is introduced into the form.

Another aspect of the invention provides a method for providing astay-in-place formwork for casting a curved structure from concrete orother curable construction material. The method comprises providing aplurality of panels and connecting a first subset of the plurality ofpanels in edge-adjacent relationships to form an outer surface, whereinthe first subset of panels comprising a first number of panels. Thefirst subset of panels are deformed such that the outer surface exhibitsa first radius of curvature. One or more panels of a second subset ofthe plurality of panels are trimmed the second subset of panelscomprises a second number of panels and the one or more panels aretrimmed by a combined transverse length. The second subset of panels areconnected in edge-adjacent relationships to form an inner surface. Thesecond subset of panels are deformed such that the inner surfaceexhibits a second radius of curvature, r2, smaller than the first radiusof curvature. The inner and outer surfaces are spaced apart to form aspace therebetween and at least a portion of the space is filled withconcrete or other curable construction material.

Another aspect of the invention provides a tool for cutting one or morepanels of a structure-lining apparatus comprising a plurality of panelsconnected at their respective transverse edges in an edge-to-edgeconnection to provide a structure-lining surface. The tool comprises abody comprising a longitudinally extending channel for slidinglyreceiving a longitudinally extending member of one of the one or morepanels and thereby forming a connection between the tool and the one ofthe one or more panels. A longitudinally extending blade protrudes fromthe body in an inward-outward direction, at a location transverselyspaced apart from the channel, such that the blade cuts at least partlythrough a thickness of the one of the one or more panels as the tool isslid along the longitudinally extending member of the one of the one ormore panels.

Another aspect of the invention provides a method for cutting one ormore panels of a structure-lining apparatus comprising a plurality ofpanels connected at their respective transverse edges in an edge-to-edgeconnection to provide a structure-lining surface. The method comprisesproviding a tool, the tool comprising a body and a longitudinallyextending blade protruding from the body in an inward-outward direction,engaging a longitudinally extending channel of the tool on alongitudinally extending member of one of the one or more panels andthereby forming a connection between the tool and the one of the one ormore panels; abutting the blade against a portion of the one of the oneor more panels, and cutting the one of the one or more panels by slidingthe tool along the longitudinally extending member.

In addition to the exemplary aspects and embodiments described above,further aspects and embodiments will become apparent by reference tofollowing detailed description and study of the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments are illustrated in referenced figures of thedrawings. It is intended that the embodiments and figures disclosedherein are to be considered illustrative rather than restrictive.

FIG. 1 is an isometric view of a portion of a structure lining apparatus10 according to a particular non-limiting embodiment of the invention.

FIG. 1A is an expanded isometric view of the structure lining apparatusof FIG. 1.

FIG. 2 is a plan view of a panel-to-panel connection according to aparticular non-limiting embodiment of the invention.

FIG. 3 is a plan view of a connector component according to a particularnon-limiting embodiment of the invention.

FIG. 4 is a plan view of another connector component according to aparticular non-limiting embodiment of the invention.

FIGS. 5A to 5G are plan views of different stages of a panel-to-panelconnection being formed according to a particular non-limitingembodiment of the invention.

FIG. 6 is a plan view of a panel according to a particular non-limitingembodiment of the invention.

FIG. 6A is a plan view of a portion of a panel and a sharp edge inposition to trim the panel according to a particular non-limitingembodiment of the invention.

FIG. 6B is a front profile view of a tool for cutting or scoring a panelaccording to a particular non-limiting embodiment of the invention.

FIG. 6C is an isometric view of the tool of FIG. 6B.

FIG. 6D is an isometric view of tool of FIG. 6B engaged with a panelaccording to a particular non-limiting embodiment of the invention.

FIG. 7 is a plan view of a double female connector according to aparticular non-limiting embodiment of the invention.

FIG. 8 is a plan view of a panel-to-panel connection using a doublefemale connector according to a particular non-limiting embodiment ofthe invention.

FIG. 9 is a plan view of a panel-to-panel connection having sealantaccording to a particular non-limiting embodiment of the invention.

FIG. 10 is a plan view of a corner piece according to a particularnon-limiting embodiment of the invention.

FIG. 11 is a plan view of a structure according to a particularnon-limiting embodiment of the invention.

FIGS. 12A and 12B are plan views of a joint cover according to aparticular non-limiting embodiment of the invention.

FIG. 13 is a plan view of a joint cover according to a particularnon-limiting embodiment of the invention.

FIG. 14 is a plan view of a structure lining apparatus according to aparticular non-limiting embodiment of the invention.

FIG. 15 is a plan view of a stay-in-place formwork according to aparticular non-limiting embodiment of the invention.

DESCRIPTION

Throughout the following description specific details are set forth inorder to provide a more thorough understanding to persons skilled in theart. However, well known elements may not have been shown or describedin detail to avoid unnecessarily obscuring the disclosure. Accordingly,the description and drawings are to be regarded in an illustrative,rather than a restrictive, sense.

Particular aspects of the invention provide modular methods andapparatus for lining one or more surfaces of concrete structures duringfabrication thereof. In particular embodiments, a portion of astructural form is lined with a structure-lining apparatus comprising aplurality of structure-lining panels and a plurality of panel-to-panelconnector components. The panels, which may extend in longitudinal andtransverse directions, are interconnected to one another in edge-to-edgerelationship at their transverse edges, by the panel-to-panel connectorcomponents, to line at least a portion of the structural form. Thepanel-to-panel connector components extend in an inward-outwarddirection from the panels. The panel-to-panel connector components may:be integrally formed with the panels; connect to the panels via suitablyconfigured connector components; and/or comprise concrete-anchoringcomponents. The panel-to-panel connector components extend in theinward-outward direction and may comprise features which may extend inthe longitudinal and transverse directions (e.g. in a plane parallel tothe panels) to provide connectors and/or concrete-anchoring surfaces. Inparticular embodiments, the connecting and/or concrete-anchoringfeatures comprise a stem which extends in the inward-outward andlongitudinal directions and, at a distance spaced apart from the panelsin the inward-outward direction, one or more arrowheads which extend inthe longitudinal and/or transverse directions to provide connectingand/or anchoring surfaces. Concrete is then poured into the form on aninterior of the lining panels and allowed to solidify in the form. Asthe concrete solidifies, the concrete-anchoring components may bond thelining panels to the resultant concrete structure.

One particular non-limiting example of a concrete structure which may belined in accordance with the invention is a wall structure—e.g. atilt-up wall structure or a pre-cast wall structure. A structural formmay be assembled on a table or a similar horizontal surface. Inparticular embodiments, a structure-lining apparatus (e.g. wall-liningapparatus) is assembled and placed within the form to cover at least aportion of the table surface. The wall-lining apparatus comprises aplurality of longitudinally and transversely extending panels connectedto one another at their transverse edges to form a wall-lining surface.Before or after interconnection with one another, the panels may be laidatop the generally horizontal table surface. In some embodiments, thewall-lining apparatus may be made to cover other surface(s) of the formas well. The wall-lining apparatus also comprises a plurality ofconcrete-anchoring components which may comprise concrete-anchoringfeatures for bonding the panels to the concrete. Such concrete-anchoringfeatures may extend from the panels in the inward-outward direction(e.g. on a stem) and then, at locations spaced apart from the panels,may extend in the longitudinal and transverse directions to provideanchoring surfaces. One or more layers of concrete are poured over topof the panels. As the concrete solidifies, the concrete-anchoringcomponents bond the lining panels to the resultant wall segment whichmay then be tilted from the generally horizontal table surface into agenerally vertical orientation.

One particular non-limiting example of a structure lining panel forlining a concrete structure may be trimmed to have a desirabletransverse dimension. In particular embodiments, the panel has two ormore panel-to-panel connector components and at least one of thepanel-to-panel connector components is transversely adjacent (i.e. notseparated by another connector component) to a corresponding breakawayfeature. The breakaway feature may comprise, for example, a score linealong which the panel can be cut, or a cutting guide. By cutting alongthe score line, or cutting guide, the transverse length of the panel maybe adjusted for a particular application. In particular embodiments, aplurality of connector components adjacent to breakaway features arespaced apart by irregular spacing transversely along a single panel. Bycombining multiple panels that are trimmed to have particular transversedimensions, it may be possible to create a concrete structure of adesired length without requiring design and fabrication of custompanels.

Structure-lining apparatus according to the invention may generally beused to line any structure formed from concrete or similar curablematerials. Without limiting the generality of the invention, the firstpart of this description presents structure-lining apparatus accordingto particular embodiments of the invention which are used in thefabrication of wall structures—e.g. wall-lining apparatus for tilt-upwalls. Such forms may comprise so called “cast-in-place” forms, in whichstructures are cast in the location, or in close proximity to thelocation, of the place where they are intended to be used or so called“pre-cast” forms, in which structures are cast in a casting location andsubsequently moved to the place where they are intended to be used.Tilt-up walls described above are one non-limiting example of structuresfabricated in pre-cast forms.

In some embodiments, structure-lining apparatus according to theinvention may be positioned such that the exterior surfaces of theedge-adjacent panels line at least a portion of an interior surface of aremovable framework.

FIG. 1 depicts a structure lining apparatus 10 according to a particularnon-limiting embodiment of the invention. In the illustrated embodiment,structure-lining apparatus 10 is a wall lining apparatus used to coverone surface of a concrete wall structure. Structure lining apparatus 10comprises a plurality of generally planar panels 12 which extend in alongitudinal dimension (shown by double-headed arrow 14) and in atransverse dimension (shown by double-headed arrow 16). Panels 12 aredisposed in edge-to-edge relationship with one another along theirtransverse edges 20, 22. It will be appreciated from the drawings, thattransverse edges 20, 22 extend in longitudinal directions 14. Theedge-to-edge configuration of panels 12 provides a structure-liningsurface 26 as described in more detail below.

It should be understood that FIGS. 1 and 1A provides a generalembodiment of a structure lining apparatus 10 having panels 12. Unlessthe context dictates otherwise, further embodiments described herein(e.g. panels 112, connector components 134, 136) may use like numberingto show that they are particular embodiments of structure liningapparatus 10. For example, panel 112 is a particular embodiment of panel12.

Wall-lining apparatus of the illustrated embodiment also comprises aplurality of connector-type concrete-anchoring components 18.Connector-type concrete-anchoring components 18 also extend in thelongitudinal direction 14 and project away from structure lining surface26 in the general direction shown by arrow 24, in FIG. 2. Direction 24is referred to herein as “inward-outward direction” 24. Connector-typeconcrete-anchoring components 18 connect transverse edges 20, 22 ofadjacent panels 12 to one another and may also help to bond panels 12 tothe concrete of the resultant wall as described in more detail below.For brevity, connector-type concrete-anchoring components 18 and otherconnector-type anchoring components described herein may occasionally bereferred to in this description as “connector components” or“connectors”.

In particular embodiments, panels 12 and connectors 18 are fabricatedfrom suitable plastic as a monolithic unit using an extrusion process.By way of non-limiting example, suitable plastics include: poly-vinylchloride (PVC), acrylonitrile butadiene styrene (ABS) or the like. Inother embodiments, panels 12 and/or connectors 18 may be fabricated fromother suitable materials, such as composite materials (e.g. acombination of one or more resins and natural and/or syntheticmaterials), for example. Although extrusion is one particular techniquefor fabricating panels 12 and connectors 18, other suitable fabricationtechniques, such as injection molding, stamping, sheet metal fabricationtechniques or the like may additionally or alternatively be used.

In some embodiments, a surface of panels 12 may be provided with anon-smooth texture (e.g. roughened and/or piled texture) or otherbondable surface (not explicitly shown) to facilitate bonding of panels12 to concrete during fabrication (e.g. as the concrete solidifies). Inparticular embodiments, the non-smooth texture panels 12 may have adimension (in inward-outward direction 24) that is greater than 2.5% ofthe thickness of panel 12 in inward-outward direction 24. In particularembodiments, the non-smooth texture of panel 12 may have a dimension (ininward-outward direction 24) that is greater than 1% of the thickness ofpanel 12 in inward-outward direction 24. In other embodiments, thenon-smooth texture of panel 12 may have a dimension (in inward-outwarddirection 24) that is greater than 0.25% of the thickness of panel 12 ininward-outward direction 24. In some embodiments, panel 12 (and/or itsinner surface) may comprise a material having physical or chemicalproperties that bonds naturally to concrete as the concrete solidifies(e.g. acrylonitrile butadiene styrene (ABS) plastic or the like).

In particular embodiments, wall-lining apparatus 10 may compriseprefabricated panels 12 having different transverse dimensions (i.e. inthe direction of double-headed arrow 16). Panels 12 may be modular inthe transverse direction, such that panels 12 of various transversesizes may be interconnected to one another using connector-typeanchoring components 18. This modularity entails that connectorcomponents 18 on edges 20, 22 of panels 12 be standardized. In someembodiments, panels 12 are adjustable in transverse length, as describedfurther below.

In some embodiments, panels 12 are prefabricated to have differentlongitudinal dimensions (double-headed arrow 14 of FIG. 1). In otherembodiments, the longitudinal dimensions of panels 12 may be cut tolength. FIG. 1 only depicts a portion of the longitudinal extension ofpanels 12. Panels 12 may be relatively thin in the inward-outwarddirection (double-headed arrow 24 in FIG. 2) in comparison to theinward-outward dimension of the resultant wall segments fabricated usingwall-lining apparatus 10. In some embodiments, the ratio of theinward-outward dimension of a wall segment to the inward-outwarddimension of a panel 12 is in a range of 10-600. In some embodiments,the ratio of the inward-outward dimension of a wall segment to theinward-outward dimension of a panel 12 is in a range of 20-300.

FIG. 2 shows detail of an edge-to-edge connection 32 of transverselyadjacent panels 12 of wall-lining apparatus 10. In particular, FIG. 2depicts a transverse cross-section (i.e. a cross section in a planedefined by the transverse and inward-outward directions) of edge-to-edgeconnection 32. In the illustrated embodiment, transverse edge 22 of afirst wall panel 12 comprises an L-shaped female connector 34 having anL-shaped transverse cross-section and opposing transverse edge 20 of atransversely adjacent second wall panel 12 comprises a complementaryL-shaped male connector 36 having an L-shaped transverse cross-section.In the illustrated embodiment, L-shaped male connector 36 is slidablyreceived in a corresponding L-shaped female connector 34 by moving thesecond wall panel 12 in the inward-outward direction 24 relative to thefirst wall panel 12. It will be appreciated that connector components34, 36 represent only one set of suitable connector components whichcould be used to connect panels 12 in edge-adjacent relationship andthat many other types of connector components could be used in place ofconnector components 34, 36. By way of non-limiting example, suchconnector components may be used to form slidable connections,deformable “snap together” connections, pivotable connections, orconnections incorporating any combination of these actions.

FIG. 3 depicts a detail view of a male connector 36A according to oneembodiment. Male connector 36 comprises a spine 36A protruding in theinward-outward direction 24 from panel 12. Spine 36A may extendlongitudinally across panel 12. In some embodiments, spine 36A extendsacross the entire longitudinal dimension of panel 12 while in otherembodiments spine 36A only extends across a portion of the longitudinalpanel 12. In further embodiments, multiple spines 36A may be spacedapart along the longitudinal dimension of panel 12. Spine 36A mayprotrude substantially orthogonally to the transverse and longitudinaldirections. In other embodiments, spine 36A may protrude from panel 12at a non-orthogonal angle.

Male connector 36 may comprise one or more arrowheads 36B, each having atransverse cross-sections shaped like an arrowhead, at locations onspine 36A, spaced apart from panel 12 in the inward-outward direction24. For example, in FIG. 2, male connector 36 comprises a firstarrowhead 36B-1 on spine 36A at a first location spaced apart from panel12 and a second arrowhead 36B-2 on spine 36A at a second location spacerelatively further apart from panel 12 in inward-outward direction 24.

First arrowhead 36B-1 may comprise any suitable transversecross-sectional shape such as a circle, a triangle, a rhombus or anarrowhead as described below. In the illustrated embodiment, atransverse cross-section of arrowhead 36B-1 comprises lobes projectingtransversely in opposing directions from spine 36A. The transverselyprojecting lobes taper in inward-outward direction 24 away from panel12. As can be seen from FIG. 2, the tapered faces 36C of first arrowhead36B-1 are relatively planar. This is not mandatory. Tapered faces 36Cmay be arcuate, stepped or the like. Tapered face 36C terminates at acorner 36D. In some embodiments, corner 36D is rounded or beveled, asillustrated. This is not mandatory, corner 36D could be a sharp corner(e.g. an acute angled corner). The intersection of corner 36D and spine36A defines a concavity 36E. Concavity 36E may comprise a lockingfeature for lockingly receiving a corresponding convexity of femaleconnector 34.

Second arrowhead 36B-2 may comprise any suitable transversecross-sectional shape and may or may not be the same transversecross-sectional shape as first arrowhead 36B-1. In the illustratedembodiment, arrowhead 36B-2 comprises lobes projecting transversely inopposing directions from spine 36A. The transversely projecting lobestaper in inward-outward direction 24 away from panel 12. As can be seenfrom FIG. 2, the tapered faces 36C of second arrowhead 36B-2 arerelatively planar. This is not mandatory. Tapered faces 36C may bearcuate, stepped or the like. Tapered face 36C terminates at a corner36D. In some embodiments, corner 36D is rounded or beveled, asillustrated. This is not mandatory, corner 36D could be a sharp corner(e.g. an acute angled corner). The intersection of corner 36D and spine36A defines a concavity 36E. Concavity 36E may comprise a lockingfeature for lockingly receiving a corresponding convexity of femaleconnector 34. Opposing tapered faces 36C of second arrowhead 36B-2 meetto define a tip 36F. Tip 36F may be rounded, as illustrated, or may be asharp corner (e.g. an acute angled corner).

Male connector 36 comprises a leg 36G extending from the base of spine36A in a generally transverse direction. Leg 36G may be arrangedorthogonally to spine 36A. This is not mandatory. Leg 36G may bearranged at any angle relative to spine 36A. At least a portion of leg36G may comprise part of panel 12.

Leg 36G may comprise a foot 36H. Leg 36G may terminate at foot 36H ormay continue past foot 36H to define a breakaway feature, as will bediscussed in more detail below. Foot 36H may protrude generally ininward-outward direction 24 from leg 36G. As illustrated in FIG. 2, foot36H may be tapered away from panel 12. Alternatively, foot 36H may havea constant transverse dimension along the entirety or substantially theentirety of its inward-outward dimension. Angle α of foot 36H may bewithin the range of 5° to 25°. For example, in the FIG. 3 embodiment,angle α is 10°.

Although depicted in some embodiments as being to the right of spine36A, leg 36G and foot 36H may also extend to the left of spine 36A. Forexample, FIG. 3 depicts a male connector 36 having legs 36G and feet 36Hextending in both the transverse directions. This is not mandatory butmay have some advantages as will be discussed further below.

Female connector 34 comprises an L-shaped receptacle comprising a firstcavity 34A, a second cavity 34B and a recess 34C all defined by a wall35. In particular, first cavity 34A is defined by a first portion 35A ofwall 35, second cavity 34B is defined by a second portion 35B of wall 35and recess 34C is defined by a recessed portion 35C of wall 35. Firstcavity 34A is connected to second cavity 34B by a neck cavity 34D andfirst portion 35A is connected to second portion 35B by a neck 35D. Anopening 34E in first cavity 34A is defined by first convexities 34F offirst portion 35A. Second convexities 34G are defined by theintersection of second part 35B and neck 35D.

As depicted in FIG. 4, first cavity 34A may correspond in shape toarrowhead 36B. This is not mandatory. Alternatively, first cavity 34Amay comprise a different shape that is complementary to the shape of oneor both of arrowheads 36B such as the circular shape of second cavity34B. Similarly, second cavity 34B may be substantially circular in shapeas depicted or may comprise a different shape that is complementary toone or both of arrowheads 36B.

Recess 34C may comprise any suitable shape to receivingly engage foot36H. For example, recessed portion 35C of wall 35 may be beveled toengage a beveled portion of foot 36H. In some embodiments, recessedportion 35C is beveled at a complementary angle to the angle of bevel offoot 36H such that foot 36H is flush against recessed portion 35C whenmale member 36 is inserted in female connector 34. Recessed portion 35Cof recess 34C may have an angle β within the range of 5° to 25°. Forexample, in the FIG. 4 embodiment, angle β is 10°. In other embodiments,a space may be left between foot 36H and recessed portion 35C to allowfor a sealant or the like to be inserted.

Convexities 34F of first portion 35A of wall 35 define opening 34E.Opening 34E may be relatively smaller that a maximum transversedimension of arrowheads 36B. Opening 34E may also be relatively largerthan a minimum transverse dimension of arrowheads 36B, such as thetransverse dimension at tip 36F, to allow tip 36F to be inserted intoopening 34E. Similarly, neck cavity 34D may be relatively smaller than amaximum transverse dimension of arrowheads 36B and relatively largerthan a minimum transverse dimension of arrowheads 36B, such as thetransverse dimension at tip 36F, to allow tip 36F to be inserted intoneck 34D.

Wall-lining apparatus 10 comprises a number of features which facilitatethe bonding of wall-lining apparatus 10, and in particularstructure-lining surface 26 defined by panels 12, to concrete. Thesefeatures may be referred to herein as concrete-anchoring components or,more generally, anchoring components.

One concrete-anchoring component of wall-lining apparatus 10 isconnector-type concrete-anchoring component 18. Connector-typeconcrete-anchoring components 18 are referred to as “connector-type”because they are also used to connect edge-adjacent panels 12 to oneanother. More particularly, in the illustrated embodiment connector-typeconcrete-anchoring components comprise female connector components 34and male connector components 36 of panels 12 for connectingedge-adjacent panels 12 to one another. Each connector-typeconcrete-anchoring component 18 extends in inward-outward direction 24from panels 12 into a proximate concrete layer. Each connector-typeconcrete-anchoring component 18 may also extend in the longitudinaldirection 14 (see FIG. 1) and may comprise concrete-anchoring features.Such concrete-anchoring features may comprise bulges, leaves,protrusions or the like with extension in longitudinal direction 14 andtransverse direction 16 (e.g. in a plane parallel to the plane panels12) at one or more locations spaced apart from panels 12. When liquidconcrete solidifies, connector-type concrete-anchoring components 18 areat least partially encased in the solid concrete. Through connectionsbetween connector-type concrete-anchoring components 18 and transverselyadjacent panels 12, the encasement of connector-type concrete-anchoringcomponents 18 helps to bond panels 12 and structure-lining surface 26 toproximate concrete layers.

FIGS. 5A-5G are partial top plan views of the formation of an exampleconnection 32 between female connector 34 and male connector 36 ofpanels 12. To form a connection 32 therebetween, male connector 36 isforced in inward-outward direction 24 into female connector 36.

FIG. 5A shows male connector 36 and female connector 34 prior to theformation of edge-to-edge connection 32. In the illustrated embodiment,tip 36F of male connector is aligned in transverse direction 16 withopening 34E of female connector 34 in preparation for forming connection32.

FIGS. 5B to 5G show various further stages in the process of formingconnection 32 between male connector 36 and female connector 34. FIG. 5Bshows male connector 36 as it begins to engage female connector 34. Thenarrow end of arrowhead 36B-2 (i.e. tip 36F) enters into opening 34E offirst cavity 34A between first wall portions 35A. As a result, firstwall portions 35A begin to resiliently deform substantially outwardly intransverse direction 16 due to the force applied by arrowhead 36B-2.This deformation results in opening 34E being widened. In theillustrated embodiment convexities 34F are shaped to complementsimilarly beveled surfaces 36C of arrowhead 36B-2, thereby facilitatingthe insertion of arrowhead 36B-2 into opening 34E of female connector 34and the corresponding widening of opening 34E due to the deformation offirst wall portions 35A.

FIG. 5C shows male connector 36 further inserted into female connector34 such that arrowhead 36B-2 is completely inserted into first cavity34A. To achieve this, opening 34E is widened to allow the largesttransverse portion of arrowhead 36B-2 to pass by convexities 34F. Afterthe largest transverse portion of arrowhead 36B-2 passes through opening34E, first wall portions 35A begin to resiliently snap back aroundarrowhead 36B-2 into a first locked position (due to restorativedeformation) once arrowhead 36B-2 passes convexities 34F. As first wallportions 35A snap back (i.e. restoratively deform), convexities 34Fengage concavities 36E of second arrowhead 36B-2 to achieve the firstlocked position.

In the first locked position of the illustrated embodiment, theextension of convexities 34F into concavities 36E secures or locksconnection 32 by providing an obstacle that hinders first wall portions35A from being moved away from one another and releasing secondarrowhead 36B-2 and hinders male connector 36 from being withdrawn fromfemale connector 34 (e.g. in inward-outward direction 24).

FIG. 5D shows male connector 36 further inserted into female connector34 such that arrowhead 36B-2 is beginning to enter neck cavity 34D. Toachieve this, neck cavity 34D is widened to allow the largest transverseportion of arrowhead 36B-2 to pass into neck cavity 34D. As a result,neck 35D begins to resiliently deform substantially outwardly intransverse direction 16 due to the force applied by arrowhead 36B-2.This deformation results in neck cavity 34D being widened. Thisdeformation also results in the widening of opening 34E which therebyeases the insertion of first arrowhead 36B-1 into first cavity 34A.

FIG. 5E shows male connector 36 even further inserted into femaleconnector 34 such that arrowhead 36B-2 has passed through neck cavity34D and has completely entered second cavity 34B. After the largesttransverse portion of arrowhead 36B-2 passes through neck cavity 34D,neck portion 35D begins to resiliently snap back (i.e. restorativelydeform) around arrowhead 36B-2 into a second locked position oncearrowhead 36B-2 passes convexities 34G. As neck 35D snaps back,convexities 34G engage concavities 36E of second arrowhead 36B-2 topartly achieve a second locked position.

At this point, first arrowhead 36B-1 has partially passed opening 34Eand neck 35D is not able to completely snap back due to the forceexerted by first arrowhead 36B-1 on opening 34E. Similar to with secondarrowhead 36B-2, convexities 34F are shaped to complement similarlybeveled surfaces 36C of first arrowhead 36B-1, thereby facilitating theinsertion of first arrowhead 36B-1 into opening 34E of female connector34 and the corresponding widening of opening 34E due to the deformationof first wall portions 35A. As illustrated in FIG. 5D, foot 36H beginsto enter recess 34C at this point.

As can be seen in FIG. 5E, second cavity 34B has a slightly largerinward-outward direction 24 dimension than does second arrowhead36B-2.To allow first arrowhead 36B-1 to completely enter first cavity34A, male connector 36 is inserted deeper into female connector 34 suchthat second arrowhead 36B-2 reaches or nearly reaches the end 34H ofsecond cavity 34B.

While arrowheads 36B enter the first and second cavities 34A, 34B, foot36H continues to enter recess 34C. In particular, foot 36H engagesrecessed portion 35C of wall 35. In some embodiments, foot 36H abutsrecessed portion 35C while in other embodiments, foot 36H may be spacedapart from recessed portion 35C when second arrowhead 36B-2 is withinsecond cavity 34B. As can be seen from FIGS. 5A-5G, leg 36G and foot 36Hoverlap with female connector 34 in inward outward direction 24 (i.e. aline in inward-outward direction 24 could pass through foot 36H andfemale connector 34). In this way, transverse edges 20, 22 ofedge-adjacent panels overlap one another in the inward-outwarddirection. In this context, overlapping in the inward-outward directionmeans that a straight line can extend in the inward-outward directionand intersect both edge-adjacent panels.

FIG. 5F shows second arrowhead 36B-2 in contact with end 34H of secondcavity 34B which thereby allows first arrowhead 36B-1 to passconvexities 34F and completely enter first cavity 34A. After the largesttransverse portion of first arrowhead 36B-1 passes through opening 34E,first wall portions 35A are able to resiliently snap back around firstarrowhead 36B-1. As second arrowhead 36B-2 remains forced into contactwith end 34H of second cavity 34B, tapered surfaces 36C of firstarrowhead 36B-1 engage neck 35D. In this way, first arrowhead 36B-1 mayforce neck 35D to widen slightly.

Meanwhile, foot 36H may be forced against recessed portion 35C, therebycausing resilient deformation of leg 36G which may flex away from spine36A. In some embodiments, such as where sealant 46 is present betweenfoot 36H and recessed portion 35C, sealant 46 may resiliently deforminstead or as well.

As the force pushing second arrowhead 36B-2 into contact with end 34H ofsecond cavity 34B is removed, neck 35D and leg 36G may snap back (due tothe resilient deformation), thereby forcing tapered surfaces 36C out ofneck cavity 34D and thereby forcing male connector 36 into a secondlocked position, as illustrated in FIG. 5G. As first wall portions 35Asnap back, convexities 34F engage concavities 36E of first arrowhead36B-1 to achieve a second locked position.

In the second locked position of the illustrated embodiment, convexities34G, 34F engage concavities 36E. The extension of convexities 34F, 34Ginto concavities 36E secures or locks connection 32 by providingmultiple obstacles that hinder first wall portions 35A, neck 35D andsecond wall portions 35B from being moved away from one another andreleasing arrowheads 36 and thereby hinder male connector 36 from beingwithdrawn from female connector 34 (e.g. in inward-outward direction24). The second locked configuration is supplemented by restorativedeformation forces applied to tapered surfaces 36C of first arrowhead36B-1 by neck 35D.

In some embodiments, an elastic or viscoelastic (e.g. flexible) seal maybe inserted between foot 36H and recessed portion 35C to help sealconnection 32 and prevent or minimize the leakage of fluids (e.g.liquids or gasses) through connection 32. In some embodiments, the sealmay be provided by a curable material (e.g. silicone, caulking, glue, acurable elastomer, a curable polyolefin and/or the like) which may beinserted between foot 36H and recessed portion 35C and may then bepermitted to cure in recess 34C. Such a curable seal may bond (e.g. anadhesive bond, a bond involving a chemical reaction, a bond involvingmelting and re-solidifying a portion of panels 12 and/or the like) toone or more of the surfaces that define recess 34C such as foot 36H orrecessed portion 35C. In some embodiments, the seal may be fabricatedfrom a material that itself bonds to the surfaces of panels 12. In someembodiments, it may be desirable to interpose a primer, a bondingadhesive and/or the like between the seal and the surface(s) whichdefine recess 34C to make and/or to enhance the bond therebetween.

It is not necessary that the seal be provided by a curable material. Insome embodiments, the seal may be provided by a suitably shaped solidflexible seal. Such a solid flexible seal may comprise elastomericmaterial, polyolefin material or any other suitable material. In someembodiments, such a solid seal may be bonded (e.g. an adhesive bond, abond involving a chemical reaction, a bond involving melting andre-solidifying a portion of panels 12 and/or the like) to one or more ofthe surfaces of recess 34C.

In some embodiments, a sealing material may be provided on some surfacesof connector components 34, 36. Such sealing material may be relativelysoft (e.g. elastomeric) when compared to the material from which theremainder of panel 12 is formed. Such sealing materials may be providedusing a co-extrusion process or coated onto connector components 34, 36after fabrication of panels 12, for example, and may help to makeconnection 32 impermeable to liquids or gasses. Suitable surfacetextures may also be applied to connector components 34, 36 to enhancethe seal or friction between components 34, 36. FIG. 9 depicts anon-limiting example embodiment of a connection 32 comprising a sealingmaterial 46 disposed within recess 34C between foot 36H and recessedportion 35C. Sealing material 46 may be co-extruded with panel 12 andmay improve the seal between male connector 36 and female connector 34.In other embodiments, sealing material 46 may be additionally oralternatively be located on the outside edge of foot 36H or may wraparound foot 36H.

In some embodiments, the transverse dimension of panels 12 may beadjustable. In particular, panels 12 may include one or more breakawayfeatures 38 to allow for shortening the transverse length of panel 12.For example, panels 12 of the FIG. 2 embodiment comprise breakawayfeatures 38 transversely adjacent to male connectors 36. In this way, ifpanel 12 is broken at breakaway feature 38, a male connector 36 willstill be at new transverse edge 20.

Breakaway features 38 may comprise any suitable structure forfacilitating the cutting or breaking of panels 12 at a desiredtransverse location. For example, breakaway features 38 may comprise ascored line, a cutting guide, some combination thereof or the like.

In particular embodiments, breakaway feature 38 may comprise a pair ofguides 38A, 38B. In some embodiments, such as is depicted in FIG. 2,first guide 38A may comprise foot 36H of male connector 36. First andsecond guides 38A, 38B may each comprise a protrusion (protruding ininward-outward direction 24 from panel 12) extending substantiallylongitudinally across panel 12. Guides 38A, 38B may define a cut-line orcutting path 38C therebetween. Cut-line 38C may comprise a notionallongitudinally extending line between first guide 38A and second guide38B. Together, guides 38A, 38B may function to aid in allowing panel 12to be cleanly cut along cut-line 38C. In some embodiments, cut line 38Cis scored.

In some embodiments, a transverse dimension of first and second guides38A, 38B tapers in inward-outward direction 24 away from panel 12 (e.g.a transverse dimension of first guide 38A closer to the inner surface ofpanel 12 is larger than a transverse dimension of first guide 38Afurther from the inner surface of panel 12), similar to feet 36H,described above. Second guide 38B may be a mirrored version of firstguide 38A (mirrored about a plane orthogonal to panel 12).

In practice, a sharp edge 75, such as a knife, the claw of a hammer, apick, a screwdriver or the like, may be drawn along cut-line 38C, guidedby first guide 38A and/or second guide 38B (i.e. to ensure that thesharp edge is maintained on cut-line 38C) to thereby cut or breakawaypanel 12 along cut-line 38C, as illustrated in FIG. 6A. In someembodiments, sharp edge 75 is merely used to score (i.e. partially cutthrough panel 12) and panel 12 is subsequently flexed or bent so as tobreak along the scored cut-line 38C. In other embodiments, cut-line 38Cis scored as part of the manufacturing process of panel 12. Cut-line 38Cmay be oriented at angle a such that the newly created foot 36H iscomplementary to recess portion 35C as described above.

In other embodiments, a specialized cutting tool having complementaryguides or tracks for receiving first guide 38A and 38B may be employedto ensure that cutting of panel 12 is clean, accurate and conforms witha desired geometry (i.e. the edge is cut at a specified angle such as,for example, to mimic angle α of foot 36H). In some embodiments, thespecialized cutting tool has complementary guides for receiving anotherfeature of panel 12, such as male connector 36. For example, FIGS. 6B-6Ddepict a cutting tool 80 according to a particular non-limitingembodiment of the invention.

Cutting tool 80 comprises a body 80A and a blade 75. Blade 75 may be atleast partly contained within a slot 80C in body 80A and may optionallyprotrude from slot 80C of body 80A. Blade 75 may extend primarily in thelongitudinal and inward-outward directions and may be relatively narrowin the transverse direction). Blade 75 may be fixed to body 80A by oneor more attachment screws 80F which may pass transversely through anaperture in blade 75 (not pictured). To prevent blade 75 from rotating(in a plane defined by the inward-outward and longitudinal directions)about attachments screw 80F, blade 75 may be held in place by one ormore set screws. For example, set screw 80D may be employed to set thedepth in the inward-outward direction at which blade 75 protrudes frombody 80A and set screw 80E may be employed to prevent rotation of blade75 about attachment screw 80F. Set screw 80E may also preventside-to-side movement of blade 75 in the transverse direction withinslot 80C. During transportation, set screw 80E may be loosened and setscrew 80D may be retracted to allow blade 75 to be retracted completelyinto slot 80C. Blade 75 may then be locked in the retracted position byre-tightening set screw 80E. In this way, it is safe to transport tool80.

Body 80A also defines a longitudinally extending channel 80B that may beshaped to complement one or more elements of panels 12 for slidablyattaching tool 80 to panel 12. For example, FIG. 6D depicts oneembodiment in which channel 80B is shaped to slidingly receive alongitudinally extending member of panel 12 such as male connector 36 ofpanel 12 Channel 80B may be slightly larger in the inward-outward andtransverse dimensions than male connector 36 to permit relative movementbetween tool 80 and panel 12 when tool 80 is engaged on male connector36 Channel 80B may also be sufficiently tight to ensure that blade 75travels along a pre-defined trajectory without departing substantiallyfrom the pre-defined trajectory because of an overly loose fit ofchannel 80B.

By engaging channel 80B of tool 80 on male connector 36 of panel 12 andsliding tool 80 along the longitudinal dimension of panel 12, it may bepossible to cut or score panel 12 using blade 75. The depth of blade 75(i.e. the length of protrusion of blade 75 from body 80A in theinward-outward direction) is greater than the difference between a totalinward-outward dimension of the longitudinally extending member of panel12 (e.g. male connector 36) and an inward-outward depth of protrusion ofthe longitudinally extending member of panel 12 into channel 80B. If thedepth of blade 75 is set to extend further than the thickness of panel12, panel 12 may be cut through as tool 80 is slid longitudinally alongmale connector 36. Alternatively, if the depth of blade 75 is set toextend only part way through the thickness of panel 12, panel 12 willonly be scored (i.e. panel 12 will not be cut through). After beingscored, panel 12 can be bent along the score line until it breaks alongthe score line.

As can be seen in FIG. 6D, when tool 80 engages male connector 36, blade75 is lined up between guides 38A, 38B such that blade 75 will cut panel12 along cut line 38C. When tool 80 is engaged with panel 12, blade 75may be orthogonal to panel 12 or may be oriented at a non-orthogonalangle (e.g. angle α) such that the newly created foot 36H iscomplementary to recess portion 35C as described above.

In some embodiments, tool 80 is handheld and is slid along an element ofpanel 12 (e.g. male connector 36) manually. In other embodiments, tool80 is attached to a motor, winch, or another machine providingmechanical advantage to aid in sliding tool 80 along panel 12 andcutting or scoring panel 12.

FIG. 1 shows an embodiment of panels 12 in which each panel 12 comprisesa plurality of transversely spaced apart male connectors 36 withcorresponding adjacent breakaway features 38. For example, FIG. 1depicts a panel 12 having seven male connectors 36 and six breakawayfeatures 38. This is not mandatory, panel 12 may comprise as few as onemale connector 36 or may comprise a plurality of male connectors 36, asdesired.

Each breakaway feature 38 along the transverse length of panel 12 allowsfor the panel to be shortened to a particular length. For eachadditional breakaway feature on panel 12, panel 12 is capable of beingshortened to another transverse length. In some embodiments, breakawayfeatures 38 (and their corresponding male connectors 36) are spacedapart evenly along the transverse length of panels 12. This may allowfor an easy determination of the length of a panel 12 or a series ofpanels 12 attached to one another. However, by spacing breakawayconnectors 38 equally, the possible transverse length variations of oneor more panels 12 is limited to multiples of that spacing.

In the illustrated embodiments, at least some male connectors 36 (withtheir corresponding adjacent breakaway features 38) are transverselyspaced apart at irregular distances along panel 12. In this way, greatervariations in the length of panels 12 can be achieved by combiningpanels 12 of different lengths.

FIG. 6 depicts an exemplary panel 112 having seven male connectors136-1, 136-2, 136-3, 136-4, 136-5, 136-6 and 136-7 (collectivelyreferred to as male connectors 136) and a single female connector 134.First male connector 136-1 is spaced apart from female connector 134 bya transverse distance 140A (measured from the center-to-center ofadjacent spines 36A), second male connector 136-2 is spaced apart fromfirst male connector 136-1 by a transverse distance 140B, third maleconnector 136-3 is spaced apart from second male connector 136-2 by atransverse distance 140C, fourth male connector 136-4 is spaced apartfrom third male connector 136-3 by a transverse distance 140D, fifthmale connector 136-5 is spaced apart from fourth male connector 136-4 bya transverse distance 140E, sixth male connector 136-6 is spaced apartfrom fifth male connector 136-5 by a transverse distance 140F andseventh male connector 136-7 is spaced apart from sixth male connector136-6 by a transverse distance 140G.

As can be seen from FIG. 6, transverse distance or transverse spacing140A may be equal to transverse distance 140B and transverse distance140C may be equal to transverse distance 140D. This is not mandatory.For example, panel 112 may comprise a number of male connectors 136 eachspaced apart by an equal transverse distance or a number of maleconnector 136s, each spaced apart by a different transverse distance. Infurther embodiments still, two or more male connectors 136 are spacedapart by different transverse distances and two or more male connectors36 are spaced apart by the same transverse distance.

In some embodiments, one or more transverse distances 140 may comprise anon-whole unit of distance (e.g. one or more transverse distances maycomprise, for example, a fraction of an inch such as 0.25 inches or afraction of a centimeter such as 1.5 cm). In this way, panels 12 can becombined to create transverse lengths of exact desired lengths, even ifthe length is not equal to a whole unit of measurement.

As can be seen from FIG. 6, and other Figures herein, breakaway features38 may be located on opposing transverse sides of spines 36A of maleconnectors 36 (e.g. on the left and right of spines 36A of maleconnectors 36 in FIG. 6). For convenience, breakaway features 38 locatedon a first side of an adjacent spine 36A (i.e. the right side asdepicted) will be referred to as breakaway features 38 and breakawayfeatures located on a second side of an adjacent spine 36A (i.e. theleft side as depicted) will be referred to as breakaway features 38′.Like breakaway features 38, breakaway features 38′ comprise a firstguide 38A′, a second guide 38B′ and a cut line 38C′ definedtherebetween. Providing breakaway features on either side of spines 36Aallows for panels 12 to be trimmed on either side of spines 36A.However, by trimming panel 12 at a breakaway feature 38′, locatedbetween a female connector 34 and a male connector 36, the trimmed panel12′ will lack a female connector 34 and will therefore not be attachableto multiple additional panels 12 each comprising a single femaleconnector 34 without adding or replacing female connector 34 in someway, such as with a double female connector 42.

FIG. 7 depicts an exemplary double female connector 42 comprising twoopposing female connectors 42A, 42B. Each of opposing female connectors42A, 42B may be similar or identical to female connectors 34 describedherein except that one of female connectors 42A, 42B may be a mirrorreflection of female connector 34 about a plane extending ininward-outward direction 24 and longitudinal direction 16. Double femaleconnector 42 may be employed to connect transverse edge 20 of a panel 12via female connector 42A to a panel 12 that has been trimmed to removefemale connector 34, as described above, via female connector 42B.Female connector 42A is spaced apart from female connector 42B by atransverse distance 140H (measured from the center of female connector42A to the center of female connector 42B). Transverse distance 140H maybe chosen as desired.

FIG. 8 depicts an exemplary connection 44 comprising panel 12 connectedto panel 12′ (e.g. a panel 12 having been trimmed to remove femaleconnector 34) by way of double female connector 42. In this way,transverse edge 20 of panel 12 is attached in an edge-to-edgerelationship with transverse edge 20′ of panel 12′. Male connector 36 ofpanel 12 is inserted into female connector 42A and male connector 36′(i.e. a mirror image of male connector 36) is inserted into femaleconnector 42B (a mirror image of female connectors 42A, 34) in a similarway as described above in relation to male connector 36 and femaleconnector 34.

By employing double female connector 42, a combination of panels 12, 12′may be created to allow for a greater variety of desired lengths ofpanels, since panels 12 can be trimmed from both transverse ends toachieve a desired length.

For purposes of illustration, the dimensions (in generic units of lengthsuch as cm, inches, feet, m, etc.) of a particular non-limiting exampleembodiment of panel 112 and double female connector 42 is set out inTable 1.

TABLE 1 Spacing of male connectors 136 on panel 112 and femaleconnectors 42A, 42B on double female connector 42 Length of spacing(generic units Section Spacing of length) A Transverse distance 140A0.75 B Transverse distance 140B 0.75 C Transverse distance 140C 3.0 DTransverse distance 140D 3.0 E Transverse distance 140E 2.5 F Transversedistance 140F 1.5 G Transverse distance 140G 0.5 H Transverse distance140H 0.5

According to the Table 1 embodiment, a single panel 112 comprises 12.0units of length. By trimming panel 112 and employing double femaleconnector 42 when necessary, it is possible to create panels 12 oflengths between 1.5 units and 12.0 units in 0.5 unit increments as setout in Table 2, below. It may also be possible to obtain many lengthsbetween 0.75 units and 12 units in 0.25 unit increments but, forsimplicity, these are not set out below.

TABLE 2 Exemplary combinations of sections for achieving desired lengthsbetween 1.5 and 12.0 units Panel Length (units of Necessary length)Sections 1.5 A, B 2.0 H, F 2.5 H, G 3.0 H, E 3.5 H, C 4.0 A, B, H, F, G4.5 A, B, C 5.0 A, B, H, C 5.5 A, B, C, H, G 6.0 H, D, E 6.5 H, C, D 7.0A, B, C, H, F, G 7.5 A, B, C, D 8.0 H, D, E, F, G 8.5 A, B, C, D, H,G9.0 H, C, D, E 9.5 H, C, D, H, E 10.0 A, B, C, D, E 10.5 H, C, D, E, F11.0 A, B, C, D, E, H, G 11.5 A, B, C, D, E, F 12.0 A, B, C, D, E, F, G

For example, if a section of panels 12 of 9.5 units is desired, a firstpanel 112 would be trimmed at breakaway feature 138′ adjacent to maleconnector 136-2 of section C and at breakaway connector 138 adjacent tomale connector 136-4 of section D. An additional panel 112 would betrimmed at breakaway feature 138′ adjacent male connector 136-4 ofsection E and at breakaway feature 138 adjacent male connector 136-5 ofsection E. A second female connector 42B of a first double femaleconnector 42 would then be attached to male connector 136-2 of sectionC, and a second double female connector 42 connected to male connector136-4 of section D. Finally, male connector 136-4 of section E would beconnected to first female connector 42A of the second double femaleconnector 42. The final product would be a chain of pieces equal inlength to 9.5 units and having a female connector 42A at one transverseedge and a male connector 136-5 at the opposite transverse edge.

It should be understood by those skilled in the art that multiple panels112 having the Table 1 dimensions and multiple double female connectors42 could be combined to achieve panel 12 combinations having anysuitable length of almost any length greater than 0.75 units, in 0.25unit increments (except for 1.75 units). It should also understood thatsimilar results could be achieved using panels 112 having differentdimensions than the Table 1 dimensions to result in smaller, bigger ordifferent incremental size increases. For example, section F could havea transverse dimension 140F of 1.0 unit instead of 1.5 units.

In some embodiments, more than just a straight section of wall may bedesired. For example, it may be desirable to provide a wall structure(e.g. a tilt-up wall structure) having one or more corners. FIG. 10depicts a corner piece 348 connectable to panels 12 to create a wallstructure having one or more corners.

Corner piece 348 extends in a longitudinal dimension (i.e. into and outof the page in FIG. 10), in the transverse dimension (shown bydouble-headed arrow 16) and in an inward-outward dimension (shown bydouble-headed arrow 24). Corner pieces 348 and/or panels 12 are disposedin edge-to-edge relationship with one another along their edges. Theedge-to-edge configuration of panels 12 and corner pieces 348 provide astructure-lining surface 26 having one or more corners.

Corner piece 348 comprises a first planar section 348-1 extending from afemale connector 334. A second planar section 348-2 extends from firstplanar section 348-1 at 45° thereto. Second planar section 348-2comprises a male connector 336-1 and a breakaway feature 338′. Maleconnector 336-1 is disposed at 45° relative to female connector 334. Inthis way, if corner piece 348 is trimmed at breakaway feature 338adjacent male connector 336-1, a first panel 12 can be attached tocorner piece 348 at connector 334 while a second panel 12 can beattached to corner piece 348 at male connector 336-1 to create a singlestructure-lining surface 26 having a 45° corner.

Corner piece 348 also comprises a third planar section 348-3 extendingat 45° from second planar section 348-2. Third planar section 348-3comprises a second male connector component 336-2 and a second breakawayfeature 338 adjacent to male connector 336-2. In this way, a first panel12 can be attached to corner piece 348 at connector 334 while a secondpanel 12 can be attached to corner piece 348 at male connector 336-2 tocreate a single structure-lining surface having a 90° corner.

Multiple corner pieces 348 may be combined to achieve a corner having aninner angle of less than 90° or to make a complex shape having multipleproximate corners.

It should be understood from the disclosure herein that portions 348-1,348-2, 348-3 may be disposed from one another at angles different from45°. For example, in another embodiment, a corner piece 348 may comprisefive portions each disposed at 22.5° to adjacent portions. As a furtherexample, a corner piece 348 may not have a total angle of 90° and couldcomprise four portions, each angled at 20° from adjacent portions tocreate a corner piece having a total angle of 60°. In some embodiments,for each additional portion, an additional corresponding male connector336 may be added. Some embodiments may comprise only one male connector336 while others comprise more than two male connectors 336.

FIG. 11 depicts an exemplary structure lining apparatus 410. In someembodiments, structure lining apparatus 410 may comprise multipledifferent sections. For example, FIG. 11 depicts a first plurality ofpanels 412 forming a first lined structure 410-1 and a second pluralityof panels 412 forming a second lined structure 410-2. It may be toocumbersome to construct the first and second lined structures 410-1,410-2 as a single structure (e.g. a single structure would be too heavyto lift into place or too large to form as one piece). Once the firstand second structures 410-1, 410-2 are cast or raised into place, it maybe desirable to attach the first lined structure 410-1 to the secondlined structure 410-2. First and second lined structures may beattached, for example, for structural or strengthening purposes, sealingpurposes or for cosmetic purposes.

A joint plug 450 and/or a joint cover 452 may be employed to assist inattaching lined structures 410-1, 410-2. For example, a curable materialsuch as caulking, epoxy, polymer, elastomer, concrete, etc. may bepoured into a space 454 between lined structures 410-1, 410-2 afterlined structures 410-1, 410-2 are in place. As the curable materialcures, a joint plug 450 may be inserted at least partially into space454. Alternatively, joint plug 450 may be used to ensure that thecurable material does not leak from space 454. Joint plug 450 may betemporarily supported from outside space 454 while the curable materialcures. Joint plug 450 may have a longitudinal dimension approximatelyequal to the longitudinal dimension of panels 12 to provide sufficientcoverage to stop the curable material from leaking.

As depicted in FIG. 11, joint plug 450 may comprise a female connector450A. Female connector 450A may be substantially similar to femaleconnectors 34 except that it has symmetrical recesses similar to recess34C. Female connector 450A may be capable of lockingly receiving malecomponents 36, as described above. As female connector 450A protrudesinto space 454, the curable material eventually hardens around it andthereby holds joint plug 450 in place.

A joint cover 452 may be employed, for example, to improve a sealbetween lined structures 410-1, 410-2 or for cosmetic reasons. Jointcover 452 may comprise a male connector 452A, substantially similar toat least a portion of male connector 36, for insertion into femaleconnector 450A of joint plug 450. Joint cover 452 may comprise a coversurface 452B that is substantially smooth. Cover surface 452B may bearcuate to provide space underneath joint cover 452 to fit joint plug450 while minimizing protrusion in inward-outward direction 24. Jointcover 452 may comprise one or more inwardly facing protrusions 452C toimprove the seal between joint cover 452 and lined structures 410-1,410-2 and/or provide structural rigidity to joint cover 452. As maleconnector 452A of joint cover 452 is inserted in to joint plug 450,protrusions 450C may be resiliently deformed against structures 410-1,410-2 and/or joint plug 450. In some embodiments, joint cover 452 may beemployed without joint plug 450 (e.g. male connector 452A is caused toprotrude into space 454 to be held in place by the curable material).

FIGS. 12A and 12B depict a joint cover 552 according to anotherembodiment. Joint cover 552, like joint cover 452, comprises a maleconnector 552A, a cover surface 552B and one or more protrusions 552C.However, joint cover 552 differs from joint cover 452 in that maleconnector 552A is not located transversely centrally on joint cover 552.Instead, male connector 552A is offset to better accommodate connectingto female connector 34 directly, without using a joint plug 450, asdepicted in FIG. 12B.

FIG. 13 depicts another non-limiting example of a joint cover 652. Jointcover 652 is substantially similar to joint cover 452 except that jointcover 652 comprises a female connector 652A instead of male connector452A. As can be seen from FIG. 13, a pair of joint covers 652 may beemployed in conjunction with a joint cover connector 654. Joint coverconnector 654 extends in the longitudinal direction and theinward-outward direction 24 between a pair of lined structures 610.Joint cover connector 654 may comprise a plurality of protrusions 654Asimilar to the protrusions 36B of male connectors 36 described herein.Female connector 652A may be connected to joint cover connector 654 byengaging female connector 652A with protrusions 654A in a similar tofashion to the way that male connector 36 is connected to femaleconnector 34. Due to the provision of a plurality of protrusions 654A,an inward-outward dimension of joint cover connector 654 may be adjustedby cutting joint cover connector 654 without limiting the ability ofjoint cover connector 654 to connect to joint covers 652. In this way, asingle joint cover connector 654 may be employed for structures 610 ofvarious inward-outward direction dimensions without having to customdesign a new joint cover connector 654 each time. In some embodiments,joint cover connector 654 may be employed to replace a joint plug 450.

In some embodiments, panels 12 may also be employed as a stay-in-placeformwork (i.e. panels 12 may comprise one half of a stay-in-placeformwork and may face additional panels 12, which form a second half ofa stay-in-place formwork and a curable material is poured and allowed tocure between the facing panels 12). FIG. 14 depicts a non-limitingexemplary embodiment of panels 12 attached to outside corner pieces 748.Outside corner pieces 748 are substantially similar to corner pieces 348in that they comprise a first portion 748-1 having a female connector734, a second portion 748-2 having a first male connector 736-1 and athird portion 748-3 having a second male connector 736-2. However,inside corner piece 748 differs from corner piece 348 in that theconnector components (e.g. female connector 734 and male connectors736-1, 736-2) are on the opposite (i.e. outside) surface as compared tothe connector components (e.g. female connector 334 and male connectors336-1, 336-2) of corner piece 348. In this way, outside corner piece 748can line surfaces having concave corners. Inside corner piece 748 alsodiffers in that first portion 748-1 comprises a third male connector734-3 and third portion 748-3 comprises a fourth male connector 734-4.

In some embodiments, panels 12 may be employed as a stay-in placeformwork for a curved structure. Where the structure is curved, panels12 may be curved to match the curvature of the structure. Additionallyor alternatively, panels 12 may be deformable such that they can bedeformed to match the curvature of the structure.

FIG. 15 depicts a structure 810 comprising outer panels 812A and innerpanels 812B (collectively referred to as panels 812). Inner and outerpanels 812A, 812B may comprise any suitable panels 12 (or 112, 212 etc.)described herein that are deformed to have a curved surface. As can beseen from FIG. 15, outer panels 812A are connected together inedge-to-edge relationships to have a radius, r_(outer) and inner panels812B are connected together in edge-to-edge relationships to have aradius, r_(inner). Radius, r_(outer) is larger than radius, r_(inner).In some embodiments, individual outer panels 812A may each be, onaverage, longer in transverse direction 816 than individual inner panels812B. Alternatively or additionally, a greater number of panels 812A maybe used than panels 812B. The difference in the length A in thetransverse direction 816 between the total of panels 812A and the totalof panels 812B may be determined by:

Δ=2π(r _(outer) −r _(inner))

In some embodiments, each panel 812 comprises multiple sections (e.g.like sections A, B, C etc. in FIG. 6 and as discussed above) separatedby male connectors 136 and corresponding breakaway components 38 (suchas depicted in FIG. 6). As described in more detail above, individualsections may be of various transverse lengths. In particular, one ormore sections of panel 812 may comprise a section having a transverselength equal to Δ. Alternatively, one or more sections of a plurality ofpanels 812 may be combined to have a transverse length equal to Δ. Inthis way, the same panels 812 that are used as outer panels 812A may beemployed as inner panels 812B by trimming one or more panels 812B tolessen the combined transverse dimension of panels by a length equal toΔ. Panels 812B may be trimmed according to any of the methods describedherein and panels 812B may be the same as or substantially similar toany of the panels described herein.

In some embodiments, the number of panels 812B to be trimmed comprises athird number, n₃, of panels 812B. If the same amount is trimmed fromeach of the n₃ panels, the amount trimmed from each of the individualpanels of the n₃ panels being trimmed panels may be determined by:

${\Delta \; {individual}} = \frac{2{\pi \left( {r_{outer} - r_{inner}} \right)}}{n_{3}}$

In other embodiments, a the transverse dimension trimmed from each ofthe trimmed panels 812B is not equal. In some embodiments, to allow foreasy removal of a transverse length Δ, the edge-most section(s) have atransverse length equal to Δ. Accordingly, all panels 812A, 812B maycomprise the same basic panel, trimmed to fit. In some embodiments,r_(outer)−r_(inner) is a standard length. For example, and withoutlimitation, r_(outer)−r_(inner) may equal 6, 8, 10 or 12 inches or mayequal 10, 15, 20 or 25 centimeters.

In some embodiments, insulation (e.g. rigid foam insulation and/or thelike) may be placed adjacent the interior surfaces of panels prior tothe introduction of concrete. After placement of insulation in thismanner, concrete or other curable material may be introduced (e.g. intothe interior of a lining system on an interior of the insulation). Sincethe insulation may have the effect of covering anchoring components 18,anchoring extensions may be provided that connect to one or moreanchoring components 18 to protrude through the insulation (e.g. throughapertures in the insulation) for anchoring into the concrete or othercurable material. For example, the anchoring extension may comprise areceptacle substantially similar to female connector 34 with anextension spine extending in the inward outward connector. In someembodiments, the extension spine comprises one or more anchoringfeatures, such as those discussed herein, for anchoring to concrete orother curable material poured over the insulation. The anchoringextensions may be attached to anchoring components using an adhesive toprovide additional resistance to detachment of anchoring components 18and the anchoring extensions.

As will be apparent to those skilled in the art in the light of theforegoing disclosure, many alterations and modifications are possible inthe practice of this invention without departing from the spirit orscope thereof. For example:

-   -   Any of the connector components described herein can be used in        conjunction with any of the forms described herein.    -   In the embodiments described herein, the structural material        used to fabricate the wall segments is concrete. This is not        necessary. In some applications, it may be desirable to use        other structural materials which may be initially be poured or        otherwise placed into forms and may subsequently solidify or        cure. In some applications, it may be desirable to use other        curable materials (e.g. curable foam insulation, curable        protective material or the like) instead of, or in addition to,        concrete.    -   In the embodiments describes herein, the outward facing surfaces        of some panels (e.g. panels 12, 112) are substantially flat. In        other embodiments, panels may be provided with corrugations in        inward-outward direction 24. Such corrugations may extend        longitudinally and/or transversely.    -   In the embodiments described above, the various features of        panels 12, 112 (e.g. connector components 34, 36 134, 136, etc.)        are substantially co-extensive with panels 12, 112 etc. in the        longitudinal dimension. This is not necessary. In some        embodiments, such features may be located at various locations        on the longitudinal dimension of panels 12, 112 etc.    -   In some embodiments, the forms described herein may be used to        fabricate walls, ceilings or floors of buildings or similar        structures. In general, the forms described above are not        limited to building structures and may be used to construct any        suitable structures formed from concrete or similar materials.        Non-limiting examples of such structures include transportation        structures (e.g. bridge supports and freeway supports),        foundations, sidewalks, pipes, tanks, beams and the like.    -   Structures (e.g. walls) fabricated according to the invention        may have curvature. Where it is desired to provide a structure        with a certain radius of curvature, panels on the inside of the        curve may be provided with a shorter length than corresponding        panels on the outside of the curve. This length difference will        accommodate for the differences in the radii of curvature        between the inside and outside of the curve. It will be        appreciated that this length difference will depend on the        thickness of the structure.    -   In addition or in the alternative to the co-extruded coating        materials and/or surface texturing described above, materials        (e.g. sealants and the like) may be provided at various        interfaces between the connector components described above to        improve the impermeability of the resulting connections to        liquids and/or gasses.    -   The description set out above makes use of a number of        directional terms (e.g. inward-outward direction 24, transverse        direction 16 and longitudinal direction 14). These directional        terms are used for ease of explanation and for explaining        relative directions. In some embodiments, the longitudinal        direction 14 may be generally vertical and the transverse and        inward-outward directions 16, 24 may be generally horizontal,        but this is not necessary. Walls and other structures fabricated        from the forms described herein need not be vertically and/or        horizontally oriented like those described above. In some        circumstances, components of the forms described herein may be        assembled in orientations different from those in which they are        ultimately used to accept concrete. However, for ease of        explanation, directional terms are used in the description to        describe the assembly of these form components. Accordingly, the        directional terms used herein should not be understood in a        literal sense but rather in a sense used to facilitate        explanation and/or directions relative to one another.    -   Many embodiments and variations are described above. Those        skilled in the art will appreciate that various aspects of any        of the above-described embodiments may be incorporated into any        of the other ones of the above-described embodiments by suitable        modification.

While a number of exemplary aspects and embodiments have been discussedabove, those of skill in the art will recognize certain modifications,permutations, additions and sub-combinations thereof. It is thereforeintended that the following appended aspects and aspects hereafterintroduced are interpreted to include all such modifications,permutations, additions and sub-combinations as are within their truespirit and scope.

What is claimed is:
 1. A structure lining apparatus comprising: a firstlongitudinally-extending lined structure, the first lined structurecomprising a first panel and a first panel connector; a secondlongitudinally-extending lined structure comprising a second panel, thesecond lined structure spaced apart from the first lined structure in atransverse direction by a gap; and a longitudinally-extending jointcover, the joint cover comprising: a joint cover panel comprising anoutwardly facing cover surface and an inwardly facing inner surface; anda joint cover connector protruding from the inner surface, the jointcover connector shaped to make a connection with the first panelconnector to thereby couple the joint cover to the first panel connectorsuch that the joint cover panel spans the gap in the transversedirection from the first lined structure to the second lined structure.2. A structure lining apparatus according to claim 1 wherein a first endof the joint cover panel is shaped to contact, and be resilientlydeformed by the first panel when the connection is made and a second endof the joint cover panel is shaped to contact, and be resilientlydeformed by, the second panel when the connection is made.
 3. Astructure lining apparatus according to claim 2 wherein the first end ofthe joint cover panel is shaped to exert restorative force against thefirst panel after the connection is made and a second end of the jointcover panel is shaped to exert restorative force against the secondpanel after the connection is made.
 4. A structure lining apparatusaccording to claim 1 wherein the joint cover panel comprises a firstdeformable protrusion extending from the inner surface and a seconddeformable protrusion extending from the inner surface; wherein: thefirst deformable protrusion is shaped to contact and be resilientlydeformed by the first panel when the connection is made; and the seconddeformable protrusion is shaped to contact and be resiliently deformedby the second panel when the connection is made.
 5. A structure liningapparatus according to claim 4 wherein: the first deformable protrusionis shaped to exert restorative force against the first panel after theconnection is made; and the second deformable protrusion is shaped toexert restorative force against the second panel after the connection ismade.
 6. A structure lining apparatus according to claim 1 wherein thejoint cover panel comprises a first plurality of deformable protrusionsextending from the inner surface and a second plurality of deformableprotrusions extending from the inner surface; wherein: each of the firstplurality of deformable protrusions is shaped to contact and beresiliently deformed by the first panel when the connection is made; andeach of the second plurality of deformable protrusions is shaped tocontact and be resiliently deformed by the second panel when theconnection is made.
 7. A structure lining apparatus according to claim 4wherein: each of the first plurality of deformable protrusions is shapedto exert restorative force against the first panel after the connectionis made; and each of the second plurality of deformable protrusions isshaped to exert restorative force against the second panel after theconnection is made.
 8. A structure lining apparatus according to claim 1wherein the joint cover panel is arcuate along a transverse dimension ofthe joint cover panel.
 9. A structure lining apparatus according toclaim 1 wherein the joint cover connector is offset from a transversemidpoint of the joint cover panel.
 10. A structure lining apparatusaccording to claim 1 wherein the joint cover connector comprises a maleconnector and the first panel connector comprises a female connector.11. A structure lining apparatus according to claim 10 wherein the maleconnector component comprises a spine protruding from the joint coverpanel in an inward-outward direction and extending longitudinally,wherein the spine comprises a first protrusion, the first protrusioncomprising a first transverse cross-section that is shaped substantiallylike an arrowhead.
 12. A structure lining apparatus according to claim11 wherein the spine comprises a second protrusion spaced apart from thefirst protrusion in the inward-outward direction, the second protrusioncomprising a second transverse cross-section that is shapedsubstantially like an arrowhead.
 13. A structure lining apparatusaccording to claim 11 wherein the first lined structure comprises afirst lined pre-cast concrete structure and the second lined structurecomprises a second lined pre-cast concrete structure.
 14. A structurelining apparatus according to claim 11 wherein the gap is filled with acurable material after the connection is formed.
 15. A structure liningapparatus according to claim 11 wherein the gap is filled with a curablematerial before the connection is formed.
 16. A structure liningapparatus according to claim 11 wherein a transverse dimension of thejoint cover panel is greater than a transverse dimension of the gap. 17.A structure lining apparatus comprising: a firstlongitudinally-extending lined structure, the first lined structurecomprising a first panel; a second longitudinally-extending linedstructure comprising a second panel, the second lined structure spacedapart from the first lined structure in a transverse direction by a gap;a longitudinally-extending joint plug protruding at least in part intothe gap, the joint plug comprising a joint plug connector; and alongitudinally-extending joint cover, the joint cover comprising: ajoint cover panel comprising an outwardly facing cover surface and aninwardly facing inner surface; and a joint cover connector protrudingfrom the inner surface, the joint cover connector shaped to make aconnection with the joint plug connector to thereby couple the jointcover to the joint plug connector such that the joint cover panel spansthe gap in the transverse direction from the first lined structure tothe second lined structure.
 18. A structure lining apparatus accordingto claim 17 wherein the gap is filled with a curable material, at leasta portion of the joint plug protrudes into the curable material and theprotrusion of the at least a portion of the joint plug into the curableholds the joint plug in place.
 19. A tool for cutting one or more panelsof a structure-lining apparatus comprising a plurality of panelsconnected at their respective transverse edges in an edge-to-edgeconnection to provide a structure-lining surface, the tool comprising: abody, the body comprising a longitudinally extending channel forslidingly receiving a longitudinally extending member of one of the oneor more panels and thereby forming a connection between the tool and theone of the one or more panels; a longitudinally extending bladeprotruding from the body in an inward-outward direction, at a locationtransversely spaced apart from the channel, such that the blade cuts atleast partly through a thickness of the one of the one or more panels asthe tool is slid along the longitudinally extending member of the one ofthe one or more panels.
 20. A tool according to claim 19 wherein atransverse cross-section of the longitudinally extending channel iscomplementary in shape to a transverse cross-section of thelongitudinally extending member.